Optical fiber cable with reinforcement

ABSTRACT

An optical communication cable includes a cable jacket formed from a first material, a plurality of core elements located within the cable jacket, and an armor layer surrounding the plurality of core elements within the cable jacket, wherein the armor layer is a multi-piece layer having a first armor segment extending a portion of the distance around the plurality of core elements and a second armor segment extending a portion of the distance around the plurality of core elements, wherein a first lateral edge of the first armor segment is adjacent a first lateral edge of the second armor segment and a second lateral edge of the first armor segment is adjacent a second lateral edge of the second armor segment such that the combination of the first armor segment and the second armor segment completely surround the plurality of core elements.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/903,184, filed Feb. 23, 2018, which is a continuation of U.S. patentapplication Ser. No. 15/426,537, filed Feb. 7, 2017, now U.S. Pat. No.9,927,588, which is a continuation of U.S. patent application Ser. No.14/317,899, filed Jun. 27, 2014, now U.S. Pat. No. 9,594,226, whichclaims the benefit of priority under 35 U.S.C. § 119 of U.S. ProvisionalApplication No. 61/892,534, filed on Oct. 18, 2013, the content of whichis relied upon and incorporated herein by reference in their entirety.

BACKGROUND

The disclosure relates generally to optical communication cables andmore particularly to optical communication cables including amulti-piece reinforcement layer, such as a multi-piece reinforcementlayer. Optical communication cables have seen increased use in a widevariety of electronics and telecommunications fields. Opticalcommunication cables contain or surround one or more opticalcommunication fibers. The cable provides structure and protection forthe optical fibers within the cable.

SUMMARY

One embodiment of the disclosure relates to an optical communicationcable. The optical communication cable includes a cable body and aplurality of elongate optical transmission elements located within thecable body. The optical communication cable includes a multi-piecereinforcement layer surrounding the plurality of optical transmissionelements. The multi-piece reinforcement layer includes a firstreinforcement sheet located within the cable body and extending aportion of the distance around the plurality of elongate opticaltransmission elements, and the first reinforcement sheet has a firstlateral edge and an opposing second lateral edge. The multi-piecereinforcement layer includes a second reinforcement sheet located withinthe cable body and extending a portion of the distance around theplurality of elongate optical transmission elements, and the secondreinforcement sheet has a first lateral edge and an opposing secondlateral edge.

An additional embodiment of the disclosure relates to an opticalcommunication cable. The optical communication cable includes anextruded cable body having an inner surface defining a passage in thecable body, and the cable body is formed from a first material. Theoptical communication cable includes a plurality of optical transmissionelements located within the passage and a reinforcement layer wrappedaround the plurality of optical transmission. The reinforcement layersurrounds the plurality of optical transmission elements within thepassage. The reinforcement layer includes a first segment and a secondsegment. The first segment is wrapped a portion of the distance aroundthe plurality of elongate optical transmission elements, and the firstsegment has a first lateral edge and an opposing second lateral edge.The second segment is wrapped a portion of the distance around theplurality of elongate optical transmission elements, and the secondsegment has a first lateral edge and an opposing second lateral edge.The optical communication cable includes a first elongate member formedfrom a second material embedded in the first material of the cable body.The first elongate member is aligned with and located exterior to thefirst lateral edge of the first segment. The optical communication cableincludes a second elongate member formed from the second materialembedded in the first material of the cable body. The second elongatemember is aligned with and located exterior to the second lateral edgeof the first segment. The first and second elongate member facilitateopening of the cable body to provide access to the plurality of opticaltransmission elements located within the passage. An outer surface ofthe first segment is bonded to the inner surface of the cable body suchthat the first segment remains bonded to the cable body upon opening ofthe cable body.

An additional embodiment of the disclosure relates to an opticalcommunication cable. The optical communication cable includes a cablebody including an inner surface defining a passage in the cable body.The optical communication cable includes an elongate central strengthmember located in the passage. The optical communication cable includesa plurality of elongate optical transmission elements wrapped around theelongate central strength member such that a portion of the length ofthe plurality of wrapped elongate optical transmission elements form aspiral portion around the elongate central strength member. The opticalcommunication cable includes a reinforcement layer wrapped around theplurality of optical transmission such that the reinforcement layersurrounds the plurality of optical transmission elements. Thereinforcement layer includes a first segment and a second segment. Thefirst segment is wrapped a portion of the distance around the pluralityof elongate optical transmission elements, and the first segment has afirst lateral edge and an opposing second lateral edge. The secondsegment is wrapped a portion of the distance around the plurality ofelongate optical transmission elements, and the second segment has afirst lateral edge and an opposing second lateral edge. Thereinforcement layer applies a radial inwardly directed force to theouter surfaces of the plurality of elongate optical transmissionelements such that the reinforcement layer acts to maintain the spiralarrangement of the spiral portion of the wrapped elongate opticaltransmission elements.

Additional features and advantages will be set forth in the detaileddescription that follows, and in part will be readily apparent to thoseskilled in the art from the description or recognized by practicing theembodiments as described in the written description and claims hereof,as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understand the natureand character of the claims.

The accompanying drawings are included to provide a furtherunderstanding and are incorporated in and constitute a part of thisspecification. The drawings illustrate one or more embodiment(s), andtogether with the description serve to explain principles and theoperation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an optical fiber cable according to anexemplary embodiment.

FIG. 2 is a cross-sectional view of the cable of FIG. 1 according to anexemplary embodiment.

FIG. 3 is a perspective view of the cable of FIG. 1 following openingaccording to an exemplary embodiment.

FIG. 4 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 5 is a cross-sectional view of the cable of FIG. 4 according to anexemplary embodiment.

FIG. 6 is a detailed perspective view showing an interlocked portion ofthe cable of FIG. 4 according to an exemplary embodiment.

FIG. 7 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 8 is a cross-sectional view of the cable of FIG. 7 according to anexemplary embodiment.

FIG. 9 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 10 is a cross-sectional view of the cable of FIG. 9 according to anexemplary embodiment.

FIG. 11 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

FIG. 12 is a perspective view of a reinforcement layer overlap sectionof an optical fiber cable according to an exemplary embodiment.

FIG. 13 is a perspective view of a reinforcement layer overlap sectionof an optical fiber cable according to an exemplary embodiment.

FIG. 14 is a perspective view of an optical fiber cable according to anexemplary embodiment.

FIG. 15 is a perspective view of an optical fiber cable according toanother exemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of an opticalcommunication cable (e.g., a fiber optic cable, an optical fiber cable,etc.) are shown. In general, the cable embodiments disclosed hereininclude one or more optical transmission elements wrapped in aprotective, reinforcement or armor material (e.g., a corrugated metalsheet of material). A cable body or jacket formed from a polymermaterial (e.g., a medium density polyethylene material) surrounds thearmored group of optical fibers. Generally, the cable jacket providesphysical support and protection to the optical fibers within the cableand the armor material provides additional reinforcement to the opticalfibers within the cable body.

In various embodiments discussed herein, the reinforcement layer isformed from at least two separate pieces or sheets of material that areeach wrapped a portion of the distance around the optical fibers.Because the reinforcement layer is formed from two pieces of material,the opposing lateral edges of each sheet of reinforcement material maybe overlapped, coupled to or bonded together to form a reinforcementlayer surrounding the optical fibers. In various embodiments, inaddition to holding the two segments of the reinforcement layer togetheraround the optical fibers, the coupling between the two segments of thereinforcement layer may also provide for additional circumferentialand/or axial rigidity to the cable. In addition, in contrast tosingle-piece wrapped armor layers typical in fiber optic cables, theindividual sections of the multi-piece reinforcement layer discussedherein do not form a complete loop, allowing both inner and outertooling to be used to more precisely shape the segments of thereinforcement layer to fit snuggly around the optical transmissionelements of the cable. In various embodiments, this precise shapingallows the armor segment to bind or restrain optical transmissionelements in a wrapped pattern (e.g., the S-Z stranding pattern) around acentral strength element.

In addition to the formation and strength functions discussed above, themulti-piece reinforcement layer discussed herein works in conjunctionwith easy access features to provide easy access to optical fiberswithin the cable, in various embodiments. In such embodiments, the cablejacket may include two or more easy access features (e.g., coextrudeddiscontinuities within the material of the cable jacket) that providefor splitting of the jacket by the user. In various embodiments, theeasy access features may be located adjacent to the lateral edges of thesegments of the reinforcement layer and the reinforcement layers may bebonded to the cable jacket. In such embodiments, when the cable jacketis opened by splitting along the easy access features, the segments ofreinforcement layer remain bonded to the cable jacket and the separatesegments of the reinforcement layer are allowed to separate from eachother. This arrangement allows for easy access to the optical fiberswithin the cable with a single opening action.

Referring to FIGS. 1 and 2, an optical communication cable, shown ascable 10, is shown according to an exemplary embodiment. Cable 10includes a cable body, shown as cable jacket 12, having an inner surface14 that defines an inner passage or cavity, shown as central bore 16. Aswill be generally understood, inner surface 14 of jacket 12 defines aninternal area or region within which the various cable componentsdiscussed below are located.

In the embodiment shown in FIG. 1, cable 10 includes a plurality of coreelements located within central bore 16. A first type of core element isan optical transmission core element, and in this embodiment, theoptical transmission core elements include optical fibers 18 that arelocated within tubes, such as buffer tubes 20. One or more additionalcore elements, shown as filler rods 22, may also be located within bore16. Filler rods 22 and buffer tubes 20 are arranged around a centralsupport, shown as central strength member 24, formed from a materialsuch as glass-reinforced plastic or metal (e.g., steel). Together,buffer tubes 20 containing optical fibers 18, filler rods 22 and centralstrength member 24 form the core 26 of cable 10. Generally, cable 10provides structure and protection to optical fibers 18 during and afterinstallation (e.g., protection during handling, protection fromelements, protection from vermin, etc.).

In various embodiments, cable 10 includes a film or membrane, shown asbinding film 28, located around buffer tubes 20 and filler rods 22 ofcable 10. Thin film 28 is an extruded thin film that cools to provide aninwardly directed force on to buffer tubes 20 and filler rods 22. Theinwardly directed force provided by film 28 assists to hold buffer tubes20 and filler rods 22 in a fixed position relative to central strengthmember 24 by increasing the normal force and therefore frictional forcebetween these components. Thus, in some embodiments, an interference fitis provided between the outer surfaces of the core elements and film 28such that film 28 acts to provide an inwardly directed force onto thecore elements of cable 10. In addition, the inwardly directed forceprovided by film 28 acts to prevent/resist unraveling of the wound coreelements. In some embodiments, a hot melt adhesive is applied to couplecore elements such as buffer tubes 20 and filler rods 22 to strengthmember 24. Thus, in various embodiments, the film of cable 10 is aconstraining element or constraining sleeve that acts to bind togetherthe core of cable 10 as discussed herein. In specific embodiments, thefilm of cable 10 is an elastic sleeve that applies a radial inwardlydirected force as discussed herein.

In various embodiments, film 28 is formed from a first material andjacket 12 is formed from a second material. In various embodiments, thefirst material is different from the second material. In some suchembodiments, the material type of the first material is different fromthe material type of the second material. In various embodiments, film28 may be formed from a variety of extruded polymer materials. Invarious embodiments, film 28 may be formed from low-density polyethylene(LDPE), polyester or polypropylene. In one embodiment, film 28 is formedfrom a linear LDPE. In one embodiment, film 28 is formed from an LDPEmaterial having a modulus of elasticity between 600 MPa and 1000 MPa,and more specifically about 800 MPa (e.g., 800 MPa plus or minus 5percent). In one embodiment, film 28 is formed from a polyester materialhaving a modulus of elasticity between 2000 MPa and 2800 MPa, and morespecifically about 2400 MPa (e.g., 2400 MPa plus or minus 5 percent). Invarious embodiments, the material of film 28 may include a coloringmaterial. In one such embodiment, film 28 may be colored the same asjacket 12. In one such embodiment, the material of film 28 may be apolymer material (e.g., LDPE, PP) including carbon black coloringmaterial, and the different material of jacket 12 may be a differentpolymer material (e.g., medium density polyethylene) that also includescarbon black coloring material. In addition, film 28 may include UVstabilizing compounds and may include weakened areas (e.g., lowerthickness areas) that facilitate tearing and opening along with othercomponents of cable 10 discussed herein.

As noted above, the material of film 28 is different from the materialof jacket 12. In some such embodiments, film 28 is formed from a firstmaterial that is extruded at an earlier time or earlier stage in cableproduction than jacket 12. In such embodiments, film 28 is formed priorto formation of jacket 12. In some such embodiments, a first extrusionprocess forms film 28 at an earlier time in cable production, and asecond extrusion process forms jacket 12 at a later time in cableproduction. In some such embodiments, the first material of film 28 andthe second material of jacket 12 are the same type of material (e.g.,both are MDPE, PP, etc.) that are associated with cable 10 at differenttime points during the production of cable 10. In other embodiments, thefirst material of film 28 and the second material of jacket 12 are thedifferent types of material (e.g., film 28 is an LDPE and jacket 12 isMDPE) and are also associated with cable 10 at different time pointsduring production of cable 10.

In various embodiments, a layer of powder, such as water absorbingpowder or particles, such as super absorbent polymer (SAP), or a waterswellable gel or liquid, is located within bore 16. In such embodiments,the inner surface of film 28 includes the water absorbent particles orother material that directly contacts the outer surfaces of buffer tubes20 and filler rods 22 under the radial inwardly directed force appliedby film 28. In other words, as discussed herein, contact between film 28and buffer tubes 20 and filler rods 22 may include contact throughcertain discontinuous intermediate or filler materials that may bepresent within bore 16, such as SAP particles, SAP yarns and/or waterswellable gels and liquids, that may be positioned within bore 16.However, as discussed herein, contact between film 28 and buffer tubes20 and filler rods 22 does not include contact through acircumferentially continuous layer of material located between film 28and buffer tubes 20. In some embodiments, the inner surface of film 28directly contacts the outer surface of buffer tubes 20 such at least aportion of the inner surface of film 28 directly physically interactswith the outer surface of the buffer tube 20 without interveningmaterial.

As shown, cable 10 includes a reinforcement sheet or layer, shown asarmor layer 30, that is located outside of film 28 in the exemplaryarrangement of FIG. 1. Armor layer 30 is wrapped around the interiorelements (including optical fibers 18) of cable 10 such that armor layer30 surrounds optical fibers 18. Armor layer 30 generally provides anadditional layer of protection to fibers 18 within cable 10, and mayprovide resistance against damage (e.g., damage caused by contact orcompression during installation, damage from the elements, damage fromrodents, etc.).

In an exemplary embodiment, armor layer 30 is located outside of binderfilm 28. In various embodiments, armor layer 30 is formed from acorrugated sheet of metal material having an alternating series ofridges and troughs. In one embodiment, the corrugated metal is steel. Inother embodiments, other non-metallic strengthening materials may beused. For example, armor layer 30 may be formed from fiberglass yarns(e.g., coated fiberglass yarns, rovings, etc.). In some embodiments,armor layer 30 may be formed from plastic materials having a modulus ofelasticity over 2 GPa, and more specifically over 2.7 GPa. Such plasticarmor layers may be used to resist animal gnawing and may includeanimal/pest repellant materials (e.g., a bitter material, a peppermaterial, synthetic tiger urine, etc.). In one embodiment, cable 10could include a layer of nylon 12 acting to resist termites.

As shown in FIGS. 1 and 2, armor layer 30 includes a first segment 32and a second segment 34. First segment 32 has a first lateral edge 36and a second lateral edge 38, and second segment 34 has first lateraledge 40 and a second lateral edge 42. In the embodiment shown, lateraledges 36, 38, 40 and 42 are substantially parallel to the longitudinalaxis of cable 10. In various embodiments discussed herein, lateral edge36 of first segment 32 is positioned adjacent to lateral edge 40 ofsecond segment 34, and lateral edge 38 of first segment 32 is positionedadjacent to lateral edge 42 of second segment 34 such that combinedfirst segment 32 and second segment 34 form a reinforcement layer thatsurrounds the plurality of core elements. While the embodimentsdiscussed herein relate primarily to cables including two-piecereinforcement layers, in other embodiments, armor layer 30 can bemulti-piece armor layers that include three, four, five or more segmentswith peripheral edges and overlaps as discussed herein.

In the embodiment of FIGS. 1 and 2, first segment 32 and second segment34 of armor layer 30 are wrapped around the core elements such thatlateral edge 36 of first segment 32 passes over or overlaps lateral edge40 of second segment 34 creating a first overlap portion 44 and thatlateral edge 38 of first segment 32 passes over or overlaps lateral edge42 of second segment 34 creating a second overlap portion 46. In variousembodiments, first segment 32 and second segment 34 are semi-cylindricalor arch-shaped elements with second segment 34 received partially withinfirst segment 32 creating overlap portions 44 and 46. In the embodimentshown in FIG. 2, overlap portion 46 is spaced approximately 180 degreesfrom overlap portion 44. In other embodiments, overlap portion 46 may bespaced more or less than 180 degrees from overlap portion 44.

In various embodiments, the sections of armor segments 32 and 34 withinoverlap portions 44 and 46 may be coupled together to help maintainmulti-piece armor layer 30 in the wrapped arrangement shown in FIGS. 1and 2. In one embodiment, a bonding agent or adhesive may be locatedbetween opposing surfaces within overlap portions 44 and 46 to bindarmor segments 32 and 34 together. In other embodiments, as discussed inmore detail below, one or more mechanical coupling arrangements can beused to couple armor segment 32 to armor segment 34.

Cable jacket 12 may include a plurality of embedded elongate members,shown as access features 50 and 52. In general, access features 50 and52 are elongate members or structures embedded within the material ofcable jacket 12. In various embodiments, access features 50 and 52 arecontiguous members that extend the length of cable jacket 12 between thefirst and second ends of the cable.

In general, cable jacket 12 is made from a first material, and accessfeatures 50 and 52 are made from a second material that is differentfrom the first material. The difference in materials provides adiscontinuity or weakness within cable jacket 12 at the location ofaccess features 50 and 52. These discontinuities provide an access pointthat allows a user of cable 10 to split cable jacket 12 when access tooptical fibers 18 is desired. In various embodiments, access features 50and 52 may be formed from a material (e.g., a polypropylene/polyethyleneblend) with low bonding relative to the material of cable jacket 12(e.g., a medium density polyethylene) that allows for jacket splittingby the user. In various embodiments, access features 50 and 52 may beformed (e.g., coextruded) as described in US 2013/0051743, filed Oct.25, 2012, which is incorporated herein by reference in its entirety. Inother embodiments, access features 50 and 52 are non-extruded elements,such as rip cords, that are embedded in the material of cable jacket 12.

As shown in FIG. 2, access features 50 and 52 are positioned withincable jacket to be aligned with and radially exterior to overlapsections 44 and 46, respectively. As shown in FIG. 3, when cable jacket12 is opened, splits 54 and 56 are formed along the length of cablejacket 12 generally at the position of access features 50 and 52,respectively. With access features aligned with overlap sections 44 and46, when cable jacket 12 is opened, armor layer 30 is also opened byseparating armor segment 32 from armor section 34 at the same time orwith the same opening action that opens cable jacket 12. Thus, in suchembodiments, when cable jacket 12 is opened, armor layer 30 is alsoopened providing access to the elements of core 26.

In some embodiments, a bonding agent (e.g., Maleic anhydride, ethyleneacrylic acid copolymer, etc.) may be used in or adjoining cable jacket12 to increase bonding between the inner surface of cable jacket 12 andthe outer surface of armor layer 30. The bonding between cable jacket 12and armor layer 30 may facilitate opening of both layers together with asingle opening action. Specifically, as cable jacket 12 is opened, armorlayer 30 may remain bound to cable jacket 12 causing armor segment 32 toseparate from armor segment 34 along overlap sections 44 and 46. Thebonding agent may also act to prevent relative sliding of edges oftwo-piece armor layer 30, and the bonding agent may also be used toprevent relative sliding of the components of any of the otherembodiments disclosed herein.

In one embodiment, the outer surfaces of armor layer 30 may include amaterial or coating (e.g., a thermoplastic exterior coating) that, whenheated, bonds to the thermoplastic of cable jacket 12. In one suchembodiment, the exterior coating of armor layer 30 is melted by the heatof the material of cable jacket 12 as the jacket is extruded over armorlayer 30 and the subsequent cooling bonds together the materials ofcable jacket 12 and the exterior coating of armor layer 30. In anotherembodiment, an induction heater is used to heat armor layer 30, causingthe exterior coating of armor layer 30 to melt and bond to the innersurface of cable jacket 12. In one embodiment, the exterior coating ofarmor layer 30 is an ethylene acrylic acid copolymer (EAAC).

As discussed above, cable 10 includes a binder film 28 located betweenthe elements of core 26 and armor layer 30. In some embodiments, theouter surface of binder film 28 is bonded to the inner surface of armorlayer 30 (e.g., with glue, bonding agent, etc.) so that when cablejacket 12 is opened utilizing access features 50 and 52, binder film 28remains bound to armor layer 30 and armor layer 30 remains bound tocable jacket 12. Thus, a single opening action splitting cable jacket 12along access features 50 and 52 acts to open armor layer 30 and binderfilm 28. In one embodiment, an induction heater is used to heat armorlayer 30 causing the material of film 28 to melt and bond to the innersurface of armor layer 30. In one such embodiment, air may be injectedinto the center of film 28, pushing film 28 outward to engage the innersurface of armor layer 30 during heating to increase bonding betweenfilm 28 and armor layer 30.

As noted above, in various embodiments, the multi-piece reinforcementlayers discussed herein may include one or more mechanical couplingstructures instead of or in conjunction with adhesive based couplings.Referring to FIGS. 4-6, cable 10 is shown including a reinforcementlayer, shown as armor layer 70, including a mechanical couplingstructure. Armor layer 70 is substantially the same as armor layer 30discussed above except as discussed herein.

Armor layer 70 includes a first segment 72 and a second segment 74.First segment 72 has a first lateral edge 76 and a second lateral edge78, and second segment 74 has a first lateral edge 80 and a secondlateral edge 82. In the embodiment shown, lateral edges 76, 78, 80 and82 are substantially parallel to the longitudinal axis of cable 10. Asshown in FIG. 5, first armor segment 72 includes a first curved or hookshaped portion 84 extending from and adjacent to first lateral edge 76and a second curved or hook shaped portion 86 extending from andadjacent to second lateral edge 78. Second armor segment 74 includes afirst curved or hook shaped portion 88 extending from and adjacent tofirst lateral edge 80 and a second curved or hook shaped portion 90extending from and adjacent to second lateral edge 82. In general, thecurved portions of first segment 72 and second segment 74 are curved andbent portions of the material armor layer 70 adjacent to the respectivelateral edges.

As shown in FIGS. 5 and 6, hook portion 84 of first armor segment 72 isinterlocked with and received within hook portion 88 of second armorsegment 74, and hook portion 86 of first armor segment 72 is interlockedwith and received within hook portion 90 of second armor segment 74.Thus, in this embodiment, armor layer 70 includes a first overlapsection 92 formed by the interlocked hook portions 84 and 88 and asecond overlap section 94 formed by the interlocked hook portions 86 and90. The engagement between the hook portions of first armor segment 72and second armor segment 74 act to couple together the segments of armorlayer 70 while still allowing for separation of the segments uponopening of cable jacket 12. In addition, the interlocked hook portionsof armor layer 70 may also provide circumferential rigidity by limitingrelative radial movement between armor segments 72 and 74. Further, thelocalized larger armor thickness at overlap sections 92 and 94 may addaxial strength to cable 10.

Referring to FIGS. 7 and 8, cable 10 is shown including a reinforcementlayer, shown as armor layer 100, including a mechanical couplingstructure, according to another exemplary embodiment. Armor layer 100 issubstantially the same as armor layer 30, except as discussed herein.

Armor layer 100 includes a first segment 102 and a second segment 104.First segment 102 has a first lateral edge 106 and a second lateral edge108, and second segment 104 has first lateral edge 110 and a secondlateral edge 112. In the embodiment shown, lateral edges 106, 108, 110and 112 extend substantially parallel to the longitudinal axis of cable10. As shown in FIG. 8, first armor segment 102 includes a radiallyextending portion 114 extending from and adjacent to first lateral edge106 and a second radially extending portion 116 extending from andadjacent to second lateral edge 108. Second armor segment 104 includes afirst radially extending portion 118 extending from and adjacent tofirst lateral edge 110 and a second radially extending portion 120extending from and adjacent to second lateral edge 112.

As shown in FIG. 8, radial portion 114 of first armor segment 102extends radially adjacent to and facing radial portion 118 of secondarmor segment 104, and radial portion 116 of first armor segment 102extends radially adjacent to and facing radial portion 120 of secondarmor segment 104. Thus, in this embodiment, armor layer 100 includes afirst overlap section 122 formed by the adjacent radial portions 114 and118 and includes a second overlap section 124 formed by the adjacentradial portions 116 and 120. In various embodiments, within overlapsection 122, an inner surface of radial portion 114 contacts an innersurface of radial portion 118, and within overlap section 124, an innersurface of radial portion 116 contacts an inner surface of radialportion 120. In this manner, armor layer 100 completely surrounds core26 of cable 10.

As shown in FIGS. 7 and 8, in various embodiments, cable 10 includes aplurality of elongate strength members embedded within the material ofcable jacket 12. In the embodiment shown, cable 10 includes a first pairof elongate strength members 126 and 128 and a second pair of elongatestrength members 130 and 132. In such embodiments, overlap section 122is located between elongate strength members 126 and 128, and overlapsection 124 is located between elongate strength members 130 and 132. Invarious embodiments, the outer surfaces of elongate strength members 126and 128 may contact or engage the outer surfaces of radial portion 114and radial portion 118, respectively, and the outer surfaces of elongatestrength members 130 and 132 may contact or engage the outer surfaces ofradial portion 116 and radial portion 120, respectively. In suchembodiments, the elongate strength members may act to maintain therelative position of first armor segment 102 and second armor segment104. In addition, the elongate strength members may also act to coupletogether first armor segment 102 and second armor segment 104 bymaintaining the engagement between the inner surfaces of radial portions114 and 118 and radial portions 116 and 120.

In various embodiments, elongate strength members 126, 128, 130 and 132may be a variety of strength members utilized in fiber optic cableconstruction. In one embodiment, elongate strength members 126, 128, 130and 132 may be glass-reinforced plastic rods. In other variousembodiments, elongate strength members 126, 128, 130 and 130 may besteel rods, aramid yarn strands or any other suitable strength member.As noted above, cable 10 may be configured with a wide variety ofoptical transmission elements. For example as shown in FIG. 7, core 26of cable 10 may include a stack 134 of a plurality of opticalcommunication elements, shown as fiber optic ribbons 136, located withinthe channel of cable jacket 12. In the embodiment shown in FIG. 7, cable10 is a single-tube cable construction that includes a single buffertube 138 and a water blocking layer, shown as water blocking tape 140,that surround fiber optic ribbons 136. In various embodiments, the waterblocking layer may be a water blocking foam, gel, woven or non-wovenmaterial.

Referring to FIGS. 9 and 10, cable 10 is shown including armor layer 100engaged with elongate strength members according to another exemplaryembodiment. The embodiment shown in FIGS. 9 and 10 is substantiallysimilar to the embodiment of FIGS. 7 and 8 except as discussed herein.As shown in the embodiment of FIGS. 9 and 10, cable 10 may include afirst elongate strength member 150 and a second elongate strength member152 embedded within the material of cable jacket 12. First elongatestrength member 150 includes an axially aligned channel or slot 154, andsecond elongate strength member 152 includes an axially aligned channelor slot 156. In this embodiment, overlap portion 122 of armor layer 100is received within slot 154, and overlap portion 124 of armor layer 100is received within slot 156. In some embodiments, the surfaces thatdefine slot 154 engage the outer surfaces of overlap portion 122 and thesurfaces that define slot 156 engage the outer surfaces of overlapportion 124. Through this engagement, first elongate strength member 150and second elongate strength member 152 act to couple first armorsegment 102 and second armor segment 104 together to form armor layer100, which surrounds the core of cable 10.

Referring to FIG. 11, a coupling arrangement for a multi-piecereinforcement layer is shown according to an exemplary embodiment.Specifically, FIG. 11 shows an overlap portion 160 of a reinforcementlayer. In this embodiment, the reinforcement layer includes a firstarmor segment 162 and a second armor segment 164. Second armor segment164 includes a plurality of tabs 166 located adjacent to lateral edge168. Tabs 166 are formed by a series of circumferentially extendingslits 170 extending circumferentially from lateral edge 168. In theembodiment shown, a section of first armor segment 162 adjacent thelateral edge is received between tabs 166 such that tabs 166 provide afriction fit to couple first armor segment 162 to second armor segment164. In such embodiments, some of tabs 166 extend above first armorsegment 162 such that the inner surface of the tabs engage the outersurface of first armor segment 162, and other tabs 166 extend belowfirst armor segment 162 such that the outer surface of the tabs engagesthe inner surface of first armor segment 162. In various embodiments, itis this engagement between tabs 166 and the adjacent armor section thatacts to couple the segments of the armor layer together. In variousembodiments, the orientation of tabs 166 alternate such that one tab 166extends above armor segment 162, the next tab 166 extends below armorsegment 162 and so on. It should be understood that one or more of theoverlap portions of the multi-piece reinforcement layers discussedherein may be formed as overlap section 160.

Referring to FIG. 12, a coupling arrangement for a multi-piecereinforcement layer is shown according to an exemplary embodiment.Specifically, FIG. 12 shows an overlap portion 180 of a reinforcementlayer. In this embodiment, the reinforcement layer includes a firstarmor segment 182 and a second armor segment 184. In this embodiment,overlap portion 180 includes a plurality of perforations 186. In variousembodiments, perforations 186 extend through both armor segment 182 andarmor segment 184 within overlap portion 180. In another embodiment,perforations 186 only extend through the upper armor segment within theoverlap section. In various embodiments, perforations 186 tend toinclude distortions and/or projecting pieces of material at the edges ofperforations 186, and these distortions and projections tend to engagethe material of the adjacent armor segment creating a friction fit thattends to hold together overlap portion 180. It should be understood thatone or more of the overlap portions of the multi-piece reinforcementlayers discussed herein may be formed as overlap section 180.

Referring to FIG. 13, a reinforcement layer, shown as armor layer 200,is shown according to an exemplary embodiment. Armor layer 200 is amulti-piece armor layer and can incorporate any of the coupling featuresdiscussed above. In the embodiment shown, armor layer 200 includes aseries of perforations 202 extending axially along armor layer 200adjacent to overlap section 204 of armor layer 200. Perforations 202extend through armor layer 200 and function as a tear-line or frangibleline to facilitate opening of armor layer 200. In such embodiments, uponthe opening of cable jacket 12 utilizing access features 50 and 52,perforations 202 allow armor layer 200 to be torn open along with cablejacket 12. In various embodiments that include a multi-piece armorlayer, the coupling between the armor layer segments at the overlapsections may be strong enough that the coupling at the overlap will noteasily decouple upon opening of cable jacket 12. In such embodiments,perforations 202 may be formed adjacent to the overlap section allowingthe armor layer to be torn open without the decoupling of the overlapsection. In another embodiment, perforations 202 may be located 180degrees from one or more of the armor overlap sections discussed herein.It should be understood that perforations 202 may be utilized inconjunction with any of the reinforcement layer embodiments discussedherein.

Referring to FIG. 14, an optical communication cable, shown as cable210, is shown according to an exemplary embodiment. Cable 210 issubstantially similar to cable 10 discussed above, except as discussedherein. Cable 210 includes an armor layer 212 and binder film 214. Asshown, in this embodiment, armor layer 212 is located between core 26and binder film 214, and binder film 214 is located between armor layer212 and cable jacket 12.

In various embodiments, the elements of core 26 are wrapped aroundcentral strength member 24 in a pattern that may include one or morespiral sections. In various embodiments, the elements of core 26 arewrapped around central strength member 24 in an S-Z stranding patternthat includes a plurality of left-handed spirally wrapped sections, aplurality of right-handed spirally wrapped sections and a plurality ofreversal sections providing the transition between each right-handed andleft-handed spirally wrapped sections. In various embodiments, armorlayer 212 is sized to impart a radial inwardly directed force onto theouter surfaces of the elements of core 26. The radial inwardly directedforce imparted by armor layer 212 increases the normal force between theelements of core 26 and central strength element 24, which acts to limitor prevent relative movement between the core elements and the centralstrength element as the elements are advanced through the cable assemblyprocess. In some such embodiments, armor layer 212 may be wrapped orcoupled around core 26 a short distance after core 26 is wrapped in thedesired pattern around central strength member 24, for example, by anoscillating nose piece used in fiber optic cable construction.

Specifically, the inwardly directed force provided by armor layer 212assists to hold buffer tubes 20 (and other core elements such as fillerrods 22 shown in FIG. 1) in a fixed position relative to centralstrength member 24 by increasing the normal force and thereforefrictional force between these components. Thus, in some embodiments, aninterference fit is provided between the outer surfaces of the coreelements and armor layer 212 such that armor layer 212 acts to providean inwardly directed force onto the core elements of cable 10. Inaddition, the inwardly directed force provided by armor layer 212 actsto prevent/resist unraveling of the wound core elements. Thus, invarious embodiments, in addition to providing structural support, armorlayer 212 is a constraining element or constraining sleeve that acts tobind together the core of cable 10. In some such embodiments, theclosing point of the armor along the manufacturing line, where the armorfirst contacts and fully surrounds the core, is within a short distancefrom the closing point of the stranded elements of the core, where thestranded elements first come together along the manufacturing line inthe pattern of stranding, such as around a central strength member, atthe end of the stranding machine. The short distance may be less thanten lay lengths of the strand profile (e.g., less than 5 lay lengths,less than one lay length), where the lay length is the averagelengthwise distance that the strand pattern has per full helicalrotation. For helically stranded elements, this would be the lengthwisedistance per helix, and for SZ stranded (or other reverse-oscillatorystranded profiles), this would be an average along a set length for arepeating profile. And/or, the short distance may be less than 5 meterson the manufacturing line, such as less than 1 meter, or even a halfmeter in some embodiments.

In various embodiments, armor layer 212 contacts the outer surfaces ofbuffer tubes 20 and any other core element such that the radial inwardlydirected force is applied as discussed herein. In various embodiments,armor layer 212 is in direct contact with the outer surfaces of buffertubes 20, and in some such embodiments there is no helically wrappedbinder located between armor layer 212 and the elements of core 26. Invarious embodiments, a layer of powder, such as water absorbing powderor particles, such as super absorbent polymer (SAP), or a waterswellable gel or liquid, is located within bore 16. In such embodiments,the inner surface of armor layer 212 may be coupled to water absorbentparticles or other material that directly contacts the outer surfaces ofbuffer tubes 20 under the radial inwardly directed force applied byarmor layer 212. In other words, as discussed herein, contact betweenarmor layer 212 and buffer tubes 20 and filler rods 22 may includecontact through certain discontinuous intermediate or filler materialsthat may be present within bore 16, such as SAP particles, SAP yarnsand/or water swellable gels and liquids, that may be positioned withinbore 16. However, as discussed herein, contact between armor layer 212and buffer tubes 20 and filler rods 22 does not include contact througha circumferentially continuous layer of material located armor layer 212and buffer tubes 20.

Similar to some of the embodiments discussed above, access features,such as access features 50 and 52 discussed above, are aligned withoverlap portions of armor layer 212. In the embodiment of FIG. 14, theouter surface of armor layer 212 is bonded to the inner surface ofbinder film 214, and the outer surface of binder film 214 is bonded tothe inner surface of cable jacket 12. Thus, in this embodiment, whencable jacket 12 is opened, utilizing features 50 and 52, armor layer 212remains bound to binder film 214 and binder film 214 remains bound tocable jacket 12. Thus, a single opening action splitting cable jacket 12along access features 50 and 52 acts to open armor layer 212 and binderfilm 214 allowing access to the elements of core 26.

In various embodiments, the optical transmission elements of core 26 caninclude a wide variety of optical fibers including multi-mode fibers,single mode fibers, bend insensitive fibers, etc. In variousembodiments, the optical transmission elements of core 26 aremicromodules of densely packed fibers with zero excess fiber lengthwithin a buffer tube. In other embodiments, the optical transmissionelements of core 26 are buffer tubes of a loose tube cable. In anotherembodiment, the optical transmission elements of core 26 are tightbuffered optical fibers. In another embodiment, the optical transmissionelements of core 26 are optical fiber ribbons.

Referring to FIG. 15, cable 10 is shown including a reinforcement layer,shown as armor layer 220, according to another exemplary embodiment.Armor layer 220 is substantially the same as armor layer 30, except asdiscussed herein. Armor layer 220 includes a first segment 222 and asecond segment 224. First segment 222 has a first lateral edge 226 and asecond lateral edge, and second segment 224 has first lateral edge 230and a second lateral edge. It should be noted that similar to the cableembodiments discussed above, armor layer 220 includes second lateraledges that mirror first lateral edge 226 of first segment 222 and firstlateral edge 230 of second segment 224. In the embodiment shown, thelateral edges of armor segments 222 and 224 extend substantiallyparallel to the longitudinal axis of cable 10. As shown in FIG. 15, agap 234 on both sides of the cable separates the adjacent lateral edgesof armor segments 222 and 224. In one embodiment, the two gaps 234 arespaced 180 degrees from one another. In one such embodiment, binder film28 includes radially extending segments, shown as portion 236. Portion236 extends radially outward and axially within gaps 234 betweenadjacent lateral edges of armor segments 222. In another embodiment, theadjacent lateral edges of armor segments 222 and 224 abut each othersuch that no gap 234 is positioned therebetween. In various embodiments,armor layer 220 may provide increased hoop strength and simple assemblydue to the lack of coupling structure between armor segments. Inaddition, because armor layer 220 does not include overlapping sections,the thickness of jacket 12 covering armor layer 220 may be thinner thanjackets covering an armor layer including an overlap.

In various embodiments, cable jacket 12 may be a variety of materialsused in cable manufacturing, such as medium density polyethylene,polyvinyl chloride (PVC), polyvinylidene difluoride (PVDF), nylon,polyester or polycarbonate and their copolymers. In addition, thematerial of cable jacket 12 may include small quantities of othermaterials or fillers that provide different properties to the materialof cable jacket 12. For example, the material of cable jacket 12 mayinclude materials that provide for coloring, UV/light blocking (e.g.,carbon black), burn resistance, etc. In various embodiments, buffertubes 20 are formed from one or more polymer material includingpolypropylene (PP), polybutylene terephthalate (PBT), polycarbonate(PC), polyamide (PA), polyoxymethylene (POM),poly(ethene-co-tetrafluoroethene) (ETFE), etc.

In various embodiments, the cable embodiments discussed herein mayinclude one or more electrical conductive elements located within bore16. In various embodiments, the conductive element may be a copperconductive element having a diameter of 12 AWG, 14 AWG, 16 AWG, 18 AWG,20 AWG, 22 AWG, 24 AWG or smaller.

While the specific cable embodiments discussed herein and shown in thefigures relate primarily to cables and core elements that have asubstantially circular cross-sectional shape defining substantiallycylindrical internal bores, in other embodiments, the cables and coreelements discussed herein may have any number of cross-section shapes.For example, in various embodiments, cable jacket 12 and/or buffer tubes20 may have an oval, elliptical, square, rectangular, triangular orother cross-sectional shape. In such embodiments, the passage or lumenof the cable or buffer tube may be the same shape or different shapethan the shape of cable jacket 12 or buffer tube. In some embodiments,cable jacket 12 and/or buffer tube may define more than one channel orpassage. In such embodiments, the multiple channels may be of the samesize and shape as each other or may each have different sizes or shapes.

The optical transmission elements discussed herein include opticalfibers that may be flexible, transparent optical fibers made of glass orplastic. The fibers may function as a waveguide to transmit lightbetween the two ends of the optical fiber. Optical fibers may include atransparent core surrounded by a transparent cladding material with alower index of refraction. Light may be kept in the core by totalinternal reflection. Glass optical fibers may comprise silica, but someother materials such as fluorozirconate, fluoroaluminate andchalcogenide glasses, as well as crystalline materials such as sapphire,may be used. The light may be guided down the core of the optical fibersby an optical cladding with a lower refractive index that traps light inthe core through total internal reflection. The cladding may be coatedby a buffer and/or another coating(s) that protects it from moistureand/or physical damage. These coatings may be UV-cured urethane acrylatecomposite materials applied to the outside of the optical fiber duringthe drawing process. The coatings may protect the strands of glassfiber.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is in no way intendedthat any particular order be inferred. In addition, as used herein, thearticle “a” is intended to include one or more than one component orelement, and is not intended to be construed as meaning only one.

It will be apparent to those skilled in the art that variousmodifications and variations can be made without departing from thespirit or scope of the disclosed embodiments. For example, armor servingas a binder, such as to constrain stranded buffer tubes and holdreversals in the stranding profile to a central strength member, is arolled single sheet or helically wrapped armor tape in some contemplatedembodiments. Since modifications, combinations, sub-combinations andvariations of the disclosed embodiments incorporating the spirit andsubstance of the embodiments may occur to persons skilled in the art,the disclosed embodiments should be construed to include everythingwithin the scope of the appended claims and their equivalents.

What is claimed is:
 1. A method of manufacturing an opticalcommunication cable, the method comprising: surrounding a plurality ofcore elements with a multi-piece armor layer, wherein the armor layercomprises: a first armor segment extending a portion of the distancearound the plurality of core elements, the first armor segment having afirst lateral edge and an opposing second lateral edge; and a secondarmor segment extending a portion of the distance around the pluralityof core elements, the second armor segment having a first lateral edgeand an opposing second lateral edge; wherein the first lateral edge ofthe first armor segment is adjacent the first lateral edge of the secondarmor segment and the second lateral edge of the first armor segment isadjacent the second lateral edge of the second armor segment such thatthe combination of the first armor segment and the second armor segmentcompletely surround the plurality of core elements; and extruding acable jacket around the armor layer.
 2. The method of claim 1, furthercomprising: extruding a film around the plurality of core elements priorto extruding the cable jacket.
 3. The method of claim 1, wherein theplurality of core elements comprises a stack of fiber optic ribbons. 4.The method of claim 1, further comprising coupling the first lateraledge of the first armor segment to the first lateral edge of the secondarmor segment and coupling the second lateral edge of the first armorsegment to the second lateral edge of the second armor segment.
 5. Themethod of claim 1, further comprising embedding a first elongatestrength member and a second elongate strength member within the cablejacket.
 6. The method claim 5, wherein the first elongate strengthmember comprises a first pair of elongate strength members and thesecond elongate strength member comprises a second pair of elongatestrength members.
 7. The method of claim 3, further comprisingapplication of a water-blocking layer to surround the stack of fiberoptic ribbons.
 8. The method of claim 7, wherein the water-blockinglayer comprises a water-blocking tape, foam or gel.